APRILIA TUONO 1000 - 2006 User manual

8104930

TUONO 1000

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First edition: January 2006

Reprint:

Produced and printed by:

VALLEY FORGE DECA

Ravenna , Modena, Torino

DECA S.r.l.

Legal and Administrative Offices

Via Vincenzo Giardini, 11

48022 Lugo (RA) - Italia -

Tel. 0545-216611

Fax 0545-216610

www.vftis.com

[email protected]

on behalf of:

aprilia s.p.a.

via G. Galilei, 1 - 30033 Noale (VE) - Italia

Tel. +39 - 041 58 29 111

Fax +39 - 041 44 10 54

www.aprilia.com

FOREWORD

NOTE This manual is an important and

integral part of your vehicle. Keep it with

your vehicle at all times, even if your

vehicle is resold.

aprilia has prepared this manual to

supply you, the user, with correct and

current information. However, since

aprilia constantly improves the design of

its vehicles, there may be slight

discrepancies between your vehicle and

the material provided in this manual. If you

have any questions regarding your vehicle,

contact your Local aprilia Dealer, as he

will have the very latest technical

information available from the factory.

For tests and repairs not expressly

described in this manual, to purchase

aprilia genuine spare parts, accessories,

and other products, and for help with

specific problems, please contact your

Local aprilia Dealer or service center.

These professionals will be able to assist

you promptly and accurately.

Thank you for choosing aprilia. Have a

great ride!

This manual is covered by copyright in all

countries; therefore, total or partial

reproduction, whatever the means

adopted, is strictly prohibited.

INTRODUCTION

This manual is divided into sections, chapters

and paragraphs, by subject. The procedures

described are laid out by single operation, and

each operation is indicated by a ♦.

The numbered parts shown in the figures are

identified in the text by the number in

parentheses or the symbol representing them.

Example (the following text is generic and

does not refer to this specific vehicle):

section

MAIN INDEPENDENT CONTROLS

chapter

STEERING LOCK

safety

warning

Never attempt to place the ignition

switch in the locked “ ” (LOCK)

position while the vehicle is moving.

paragraph

OPERATION

operation To lock the steering:

♦ Turn the handlebar completely to the

left or to the right.

position (2)

♦ Turn the key (2) to the “ ” position.

symbol “ ”

♦ Press the key and turn it to the “ ”

♦ Remove the key.

WARNING

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SAFETY WARNINGS

The symbols and warnings used throughout

this manual have the following meanings:

Safety Warning: When you find this

symbol on the vehicle or in the

manual, be careful of the potential

risk of personal injury or death.

Disregarding the instructions identified by

this symbol may compromise the safety of

the user, the motorcycle and third parties.

WARNING

Indicates a potential hazard which may

result in serious injury or even death.

WARNING

Indicates a potential hazard which may

result in personal injury or damage to the

vehicle or other property.

NOTE The word “NOTE” in this manual

identifies important information or instructions.

GENERAL SAFETY RULES

CARBON MONOXIDE

When an operation must be performed with

the engine running, position the motorcycle

outdoors in a well-ventilated area. Never run

the engine in an enclosed place.

Use an exhaust emission extraction system

when working indoors.

WARNING

Exhaust fumes contain carbon monoxide,

a poisonous gas which, if inhaled, may

cause loss of consciousness or even

death.

WARNING

Carbon monoxide is both colorless and

odorless, and cannot be detected by

smell, vision, or any other sense. Avoid

inhaling exhaust fumes under any

circumstances.

GASOLINE

Keep gasoline away from children. Gasoline

is also poisonous. Never attempt to siphon

gasoline using your mouth. Never allow

gasoline to come in contact with skin. If you

should accidentally spill gasoline on yourself,

remove contaminated clothing immediately

and wash the affected area with hot water and

soap. Should you accidentally swallow

gasoline, do not induce vomiting. Drink large

quantities of clear water or milk and

immediately seek medical attention. Should

you accidentally get gasoline in your eyes,

rinse abundantly with cool, clear water and

immediately seek medical attention.

WARNING

Gasoline is extremely flammable and

becomes explosive under certain

conditions.

KEEP GASOLINE AWAY FROM

CHILDREN.

HOT COMPONENTS

WARNING

The engine and exhaust component parts,

as well as the braking system, become

very hot when running and will stay hot for

some time after the vehicle and the engine

have been stopped. Before handling any

vehicle component after riding, make sure

that it has cooled down and is safe to

handle.

USED ENGINE OIL

WARNING

Use latex gloves for maintenance

operations that require contact with used

oil. Prolonged or repeated contact with

used engine oil may cause skin cancer.

Although this is unlikely unless you

handle used oil on a daily basis, it is

advisable to thoroughly wash your hands

with soap and water after handling used

oil.

KEEP OIL AWAY FROM CHILDREN.

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BRAKE FLUID

WARNING

Brake fluid is extremely poisonous. Never

swallow brake fluid. Should brake fluid

accidentally be swallowed, drink large

quantities of milk or clear water and

immediately seek medical attention. Brake

fluid is highly irritant. Avoid contact with

the skin and eyes. In case of contact with

brake fluid, remove contaminated

clothing, wash the affected area with soap

and warm water and immediately seek

medical attention. In case of contact with

the eyes, rinse abundantly with cool, clean

water and immediately seek medical

attention.

KEEP BRAKE FLUID AWAY FROM

CHILDREN.

CLUTCH FLUID

CAUTION

Clutch fluid is extremely poisonous. Never

swallow clutch fluid. Should clutch fluid

accidentally be swallowed, drink large

quantities of milk or clear water and

immediately seek medical attention.

Clutch fluid is highly irritant. Avoid contact

with the skin and eyes. In case of contact

with clutch fluid, remove contaminated

clothing, wash the affected area with soap

and warm water and immediately seek

medical attention. In case of contact with

the eyes, rinse abundantly with cool, clean

water and immediately seek medical

attention.

KEEP CLUTCH FLUID AWAY FROM

CHILDREN.

COOLANT

Under certain conditions, the ethylene glycol

contained in the engine coolant is flammable:

its flame is invisible, but can still cause burns.

WARNING

Avoid spilling coolant onto hot engine

parts. It may ignite and produce invisible

flames.

Coolant (ethylene glycol) can cause skin

irritation and is poisonous if swallowed.

Coolant and coolant/water mixtures are

sweet to the taste and brightly colored,

they are therefore highly attractive to pets

and children. Take extra precautions to

keep new and used coolant out of reach of

children and animals.

KEEP COOLANT AWAY FROM

CHILDREN.

Burn hazards.

Do not remove the radiator cap when the

engine is hot. Wait until the engine has

completely cooled down. The coolant is

under pressure and may splash out and

cause burns.

BATTERY HYDROGEN GAS AND

ELECTROLYTE

WARNING

The battery gives off toxic and explosive

gases; keep the battery away from

sources of ignition such as cigarettes,

flames and sparks. Make sure the area is

well ventilated when servicing or refilling

the battery.

During recharging and use, make sure

that the room is properly ventilated and

avoid inhaling the gases released during

recharging operations.

The battery contains sulfuric acid

(electrolyte). Contact with the skin or

eyes may cause serious burns. Always

wear protective clothing, rubber gloves,

and tight fitting goggles or a face shield

when working around the battery,

especially when filling the battery with

either water or electrolyte.

In case of contact with the skin, rinse

immediately with plenty of water. In case

of contact with the eyes, flush with

plenty of water for at least 15 minutes.

Immediately seek medical attention.

The electrolyte is poisonous.

If the electrolyte is accidentally

swallowed, drink large quantities of

water or milk and then milk of magnesia

or vegetable oil. Immediately seek

medical attention.

KEEP BATTERIES AND ELECTROLYTE

AWAY FROM CHILDREN.

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WARNING - PRECAUTIONS -

GENERAL ADVICE

Before starting the engine, read this manual

carefully, and in particular the chapters

“WARNINGS - PRECAUTIONS - GENERAL

ADVICE” and “SAFE DRIVE” see pg. 19.

Your safety and that of those around you

depends not only on your skill as a rider, but

also on the knowledge you have of your

vehicle and riding safely. Therefore it is

essential that you avoid using your vehicle on

public streets or highways until you have

received training from a qualified safety

organization such as the Motorcycle Safety

Foundation, and are properly trained and

licensed.

REPORTING DEFECTS THAT

AFFECT SAFETY

If you believe that your vehicle has a defect

that could cause an accident or result in injury

or death, you should immediately inform the

National Highway Traffic Safety

Administration (NHTSA) in addition to

notifying aprilia. If the NHTSA receives

similar complaints, it may open an

investigation, and if it finds that a safety defect

exists in a group of vehicles, it may order a

recall and remedy campaign. However, the

NHTSA cannot become involved in individual

problems between you, your dealer, or

aprilia. To contact the NHTSA, you may

either call the Auto Safety Hotline toll free at

1-800-424-9393 (or 366-0123 in the

Washington, D.C. area) or write to: NHTSA,

U.S. Department of Transportation,

Washington, D.C. 20590.

The Hotline also provides other information

regarding motor vehicle safety.

ROAD REGULATIONS

AND USE OF THE VEHICLE

Rules of the road vary from country to country.

It is essential that you be aware of and

understand the rules of the road of the country

in which your vehicle will be used.

WARNING

This vehicle has been designed and

produced for use only on paved roads. It is

not designed to be used on graded dirt

roads or trails, even if smooth. It is not

designed for off-road competition, or for

cross country riding. Do not use this

vehicle on rough or unimproved surfaces,

or in other off-road areas. Failure to

observe this warning could lead to an

upset and result in injury and even death.

NOISE EMISSION WARRANTY

aprilia s.p.a. warrants that, at the time of

sale, this exhaust system meets all applicable

U.S. EPA Federal noise standards. This

warranty extends to the first person who buys

this exhaust system for purposes other than

resale, and to all subsequent buyers.

Warranty claims should be addressed to:

aprilia USA Inc.

109 Smoke Hill Lane, Suite 190

Woodstock, GA 30188

USA

Tel 001 770 592 2261

Fax 001 770 592 4878

INFORMATION ON THE NOISE AND

EXHAUST GAS EMISSION CONTROL

SYSTEM

ORIGIN OF THE EMISSIONS

The combustion process produces

carbon monoxide and hydrocarbons.

Hydrocarbon control is very important,

because under certain conditions they

react to exposure to sunlight and produce

photochemical smog.

Carbon monoxide does not react in the

same way, but is toxic and poisonous.

aprilia utilizes “lean” carburetor settings

and other systems to reduce the

production of carbon monoxide and

hydrocarbons.

TAMPERING WARNING

Tampering with the noise control system is

prohibited. Federal law prohibits the following

acts or causing thereof:

a) The removal or rendering inoperative by

any person other than for purposes of

maintenance, repair, or replacement, of

any device or element of design

incorporated into any new vehicle for the

purpose of noise control prior to its sale or

delivery to the ultimate purchaser or while

it is in use, or

b) The use of the vehicle after such device or

element of design has been removed or

rendered inoperative by any person.

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Among those acts presumed to constitute

tampering are the acts listed below:

a) Removal of, or puncturing the muffler,

baffles, header pipes or any other

component which conducts exhaust

gases.

b) Removal or puncturing of any part of the

intake system.

c) Lack of proper maintenance.

d) Replacing any moving part of the

vehicle, or parts of the exhaust or intake

system, with parts other than those

specified by the manufacturer.

CAUTION

This product should be checked for

repair or replacement if the vehicle

noise has increased significantly

through use. Otherwise, the owner may

become subject to penalties under state

and local ordinances.

PROBLEMS THAT MAY AFFECT

VEHICLE EMISSIONS

If any of the following symptoms are

observed, immediately have your vehicle

inspected and repaired by your Local

aprilia Dealer.

Symptoms:

– Difficult starting or stalling after starting.

– Irregular idle.

– Misfiring or backfiring during

acceleration.

– After-burning (backfiring).

– Poor engine performance, degraded

handling, or poor fuel economy.

VEHICLE IDENTIFICATION NUMBER

(V.I.N.) (FRAME NUMBER)

Every vehicle produced by aprilia receives

a vehicle identification number (V.I.N.)

stamped:

– on the steering head of the frame (A), as

shown above;

and also:

– on the identification plate (B) which is

located on the front portion near the

steering head of the frame.

INFORMATION CONTAINED IN THE

VEHICLE IDENTIFICATION

NUMBER

Description of the vehicle identification

number (V.I.N.), stamped on the steering

head of the frame (A) and on the

identification plate (B).

A

B

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DIGIT MEANING

1) Manufacturer’s identification

alphanumeric code.

2) Vehicle type.

3) Model.

4) Country for which the vehicle is

intended.

5) #= Check digit number.

6) Model year.

7) Assembling factory designation

(N = NOALE-VE- ,

S = SCORZÉ -VE- ,

0 = NOT SPECIFIED).

8) Sequential serial number.

-RRT-

GVWR: 401 KG (883 LB)

GAWR: F. 152 KG (335 LB) WITH 120/65 ZR 17 (56W) OR

120/70 ZR 17 (58 W) TIRE 17 x 3.50 - DOT-D RIM, AT 250 KPA (36 PSI) COLD

GAWR: R. 249 KG (548 LB) WITH 180/55 ZR 17 (73 W) OR 190/50 ZR 17 (73 W) OR

190/55 ZR 17 (75 W) TIRE 17 x 6.00 - DOT-D RIM, AT 280 KPA (41 PSI) COLD

THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL MOTOR

VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF

MANUFACTURE SHOWN ABOVE.

MANUFACTURED BY APRILIA

MOTORCYCLE

ZD4RRT00#Y0000000

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POSITION OF THE ADHESIVE WARNING LABELS

11

12

14

1

4

13

14

2

3

6

7

5

9

10

810

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ADHESIVE WARNING LABELS CHART

Ref. Description

1

2

FOR STATE OF CALIFORNIA ONLY.

3

4

-RRT-

GVWR: 401 KG (883 LB)

GAWR: F. 152 KG (335 LB) WITH 120/65 ZR 17 (56W) OR

120/70 ZR 17 (58 W) TIRE 17 x 3.50 - DOT-D RIM, AT 250 KPA (36 PSI) COLD

GAWR: R. 249 KG (548 LB) WITH 180/55 ZR 17 (73 W) OR 190/50 ZR 17 (73 W) OR

190/55 ZR 17 (75 W) TIRE 17 x 6.00 - DOT-D RIM, AT 280 KPA (41 PSI) COLD

THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. FEDERAL MOTOR

VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF

MANUFACTURE SHOWN ABOVE.

MANUFACTURED BY APRILIA

MOTORCYCLE

AIR

ATMOSPHERE

MANIFOLD VACUUM PORT

NARROW PASSAGE

VENTILATION VALVE

AIR

FUEL VAPOR

AIR BOX

FUEL TANK

CARBON

CANISTER

EVAP FAMILY: 7ASPE0024RRT

HOSE ROUTING DIAGRAM

RRT

5

6

7

8

Follow X

Ref. Description

This battery is completely sealed.

Do not attempt to remove the cap.

Replace with sealed battery only.

Always keep the battery charghed

(see Owner's Manual).

Never disconnect the battery

or regulator with the engine running.

This will completely destroy the entire

electrical system

Never install accessories or replacement parts not

approved by Aprilia as original equipment.

This can degrade the handling and safety of your motorcycle,

and can cause an upset with subsequent accident and

serious injury or even death.

The stability and safety of any motorcycle is adversely

affected by the addition of any load carrying accessory.

See owner's manual.

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9

10

11

12

13

Ref. Description

-Wear a helmet, eye protection, and bright protective clothing.

-Don't ride after consuming alcohol or other drugs.

-Slow down on slippery surface, unfamiliar terrain or when visibility is reduced.

- Read owner's manual carefully.

-Failure to follow these warnings can lead to an accident and serious injuries or death.

-USE UNLEADED FUEL MINIMUM OCTANE RATING (R + M) / 2 METHOD 90.

- See owner's manual for the correct running in and maintenance of the vehicle.

Do not allow key chain and any other

item to fall between the steering head and the body of motorcycle.

This can cause loss of control.

Do not use any tire other than those reccomended and approved by Aprilia. Maintain

proper tire inflation. Do not use any tire with less than 1/8" (3mm) tread remaining.

Do not repair any tire, nor use repaired tire. Do not ride your motorcycle overloaded

or with an unbalanced load. Failure to follow these warnings can lead to an accident

and serious injures or death. Always ensure that the chain is correctly adjusted.

See owner's manual.

(36)

280

(41)

230

250

(36)

250

(33)

250

(36)

280

190/55 ZR 17"(75W)

(41)

(58W)

Pirelli - Metzler

Michelin

Dunlop

Pirelli - Metzler

Michelin

Dunlop

RRT

(56W)

(73W)

kpa - (psi)

MOTORCTCLE NOISE EMISSION CONTROL INFORMATION

THIS 2007 ASPRRT0998 MOTORCYCLE. ZD41016 MEETS EPA NOISE EMISSION

REQUIREMENTS OF 80 dBA AT 5225 closing r.p.m. BY FEDERAL TEST PROCEDURE.

MODIFICATIONS WHICH CAUSE THIS MOTORCYCLE TO EXEED FEDERAL NOISE

STANDARDS ARE PROHIBITED BY FEDERAL LAW.

SEE OWNUER'S MANUAL.

RRTT

RRT

VEHICLE EMISSION CONTROL INFORMATION

ENGINE DISPLACEMENT: 998 cc

ENGINE FAMILY: 7ASPC0.99RRT

THIS VEHICLE CONFORMS TO U.S. EPA AND CALIFORNIA

REGULATIONS APPLICABLE TO 2007 MODEL YEAR

NEW MOTORCYCLES AND IS CERTIFIED TO

0.8 HC+NOx G/KM ENGINE FAMILY EXHAUST

EMISSION STANDARD IN CALIFORNIA.

ENGINE EXHAUST CONTROL

SYSTEM: HO2S-2TWC-

SFI

ENGINE TUNE UP SPECIFICATIONS

IGNITION TIMING: 23.2˚ ± 2˚ AT 2800 RPM

IDLE SPEED: 1250 ± 100 RPM IN NEUTRAL

VALVE CLEARANCE:

INLET 0.0047÷0.0067 inch (0.12÷0.17 mm)

OUTLET 0.0091÷0.0110 inch (0.23÷0.28 mm)

SPARK PLUG: NGK R DCPR9E

FUEL: MINIMUM OCTANE RATING (M+R)/2 METHOD 90

OIL: ENGINE OIL VISCOSITY SAE 15W-50

PART 575.6, CONSUMER INFORMATION

14

Muffler stamping.

Ref. Description

aprilia World Service USA, Inc.

109 Smoke Hill Lane Suite 190 GA, 30188 Woodstock

Reporting Safety Defects

If you believe that your vehicle has a defect which could cause a crash or could cause

injury or death, you should immediately inform the National Highway Traffic Safety

Administration (NHTSA) in addition to notifying aprilia World Service USA, Inc.

If NHTSA receives similar complaints, it may open an investigation, and if it finds that a

safety defect exists in a group of vehicles, it may order a recall and remedy campaign.

However, NHTSA cannot become involved in any individual problems between you,

your dealer, or

aprilia World Service USA, Inc.

To contact NHTSA you may either call the Auto Safety Hotline toll-free at 1-888-327-4236

or write to:

NHTSA

U.S. DEPARTMENT of TRANSPORTATION

400 7th Street SW, (NVS-223) Washington, DC 20590

You can also obtain other information about motor vehicle safety from the Hotline.

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CALIFORNIA EVAPORATIVE

EMISSION SYSTEM

FOR STATE OF CALIFORNIA ONLY.

The system consists of:

1) Coal filter

2) Choke hold

3) Valve

4) Canister support plate

5) M6x20* flanged TE screw

6) 4x8 tube

7) 5.5x10 fuel line

8) D11.3 tie wrap

9) D10.1* tie wrap

10)D8* tie wrap

11)D9.1* tie wrap

12)D10.6 cable runner

7

8

7

6

2

6

8

4

5

7

8

11

1

10

3

11

9

12

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aprilia s.p.a. - EMISSION

CONTROL SYSTEM

WARRANTY STATEMENT

YOUR WARRANTY RIGHTS

AND OBLIGATIONS

The California Air Resources Board and

aprilia s.p.a. (hereinafter “aprilia”) are

pleased to explain the emission control

system warranty on your 1999 and later

motorcycle. In California new motor

vehicles must be designed, built and

equipped to meet the State’s stringent

antismog standards. aprilia must warrant

the emission control system on your

motorcycle for the periods of time listed

below provided there has been no abuse,

neglect or improper maintenance of your

motorcycle.

Your emission control system may include

parts such as the carburetor or fuel

injection system, the ignition system,

catalytic converter and engine computer.

Also included may be hoses, belts,

connectors and other emission-related

assemblies.

Where a warrantable condition exists,

aprilia will repair your motorcycle at no cost

to you, including diagnosis, parts and

labor.

MANUFACTURER’S EMISSIONS

SYSTEM WARRANTY COVERAGE

Class I motorcycles (50 – 169 cm

3

): for a

period of use of five (5) years or 12,000

kilometers (7,456 miles), whichever occurs

first.

Class II motorcycles (170 – 279 cm

3

): for a

period of use of five (5) years or 18,000

kilometers (11,185 miles), whichever

occurs first.

Class III motorcycles (280 cm

3

and larger):

for a period of use of five (5) years or

30,000 kilometers (18,641 miles),

whichever occurs first.

If an emission-related part on your

motorcycle is defective, the part will be

repaired or replaced by aprilia. This is

your emission control system DEFECTS

WARRANTY.

OWNER’S WARRANTY

RESPONSIBILITIES

– As the motorcycle owner, you are

responsible for the performance of the

required maintenance listed in your

owner’s manual. aprilia recommends

that you retain all receipts covering

maintenance on your motorcycle, but

aprilia cannot deny warranty solely for

the lack of receipts or for your failure to

ensure the performance of all scheduled

maintenance.

– You are responsible for presenting your

motorcycle to an aprilia dealer as soon

as a problem arises. The warranty

repairs should be completed in a

reasonable amount of time, not to

exceed 30 days.

– As the motorcycle owner, you should be

aware that aprilia may deny your

warranty coverage if your motorcycle or

a part has failed due to abuse, neglect,

improper maintenance or unapproved

modifications.

If you have any questions regarding your

warranty rights and responsibilities, you

should contact aprilia USA, Inc., 10933

Crabapple Road, Suite 100, Roswell, GA

3007, or the California Air Resources

Board at P.O. Box 8001, 9528 Telstar

Avenue, El Monte, CA 91734-8001.

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aprilia s.p.a. - LIMITED

WARRANTY ON EMISSION

CONTROL SYSTEM

aprilia s.p.a., Via G. Galilei, 1, 30033

Noale (VE) Italy (hereinafter “aprilia”)

warrants that each new 1999 and after

aprilia motorcycle, that includes as

standard equipment a headlight, taillight

and stoplight, and is street legal:

A. is designed, built and equipped so as to

conform at the time of initial retail

purchase with all applicable regulations

of the United States Environmental

Protection Agency, and the California Air

Resources Board; and

B. is free from defects in material and

workmanship which cause such

motorcycle to fail to conform with

applicable regulations of the United

States Environmental Protection Agency

or the California Air Resources Board for

a period of use, depending on the engine

displacement, of 12,000 kilometers

(7,456 miles), if the motorcycle’s engine

displacement is less than 170 cubic

centimeters; of 18,000 kilometers

(11,185 miles), if the motorcycle’s engine

displacement is equal to or greater than

170 cubic centimeters but less than 280

cubic centimeters; or of 30,000

kilometers (18,641 miles), if the

motorcycle’s engine displacement is 280

cubic centimeters or greater; or 5 (five)

years from the date of initial retail

delivery, whichever occurs first.

I. COVERAGE. Warranty defects shall be

remedied during customary business

hours at any authorized aprilia

motorcycle dealer located within the

United States of America in compliance

with the Clean Air Act and applicable

regulations of the United States

Environmental Protection Agency and

the California Air Resources Board. Any

part or parts replaced under this

warranty shall become the property of

aprilia.

In the State of California only, emission

related warranted parts are specifically

defined by the state’s Emission Warranty

Parts List. These warranted parts are:

carburetor and internal parts; intake

manifold; fuel tank; fuel injection system;

spark advance mechanism; crankcase

breather; air cutoff valves; fuel tank cap

for evaporative emission controlled

vehicles; oil filler cap; pressure control

valve; fuel/vapor separator; canister;

igniters; breaker governors; ignition

coils; ignition wires; ignition points;

condensers, and spark plugs if failure

occurs prior to the first scheduled

replacement; and hoses, clamps, fittings

and tubing used directly in these parts.

Since emission related parts may vary

from model to model, certain models

may not contain all of these parts and

certain models may contain functionally

equivalent parts.

In the State of California only, Emission

Control System emergency repairs, as

provided for in the California

Administrative Code, may be performed

by other than an authorized aprilia

dealer. An emergency situation occurs

when an authorized aprilia dealer is not

reasonably available, a part is not

available within 30 days, or a repair is

not complete within 30 days. Any

replacement part can be used in an

emergency repair. aprilia will

reimburse the owner for the expenses,

including diagnosis, not to exceed

aprilia’s suggested retail price for all

warranted parts replaced and labor

charges based on aprilia’s

recommended time allowance for the

warranty repair and the geographically

appropriate hourly labor rate. The owner

may be required to keep receipts and

failed parts in order to receive

compensation.

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use and maintenance TUONO 1000

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14

II. LIMITATIONS. This Emission Control

System warranty shall not cover any of

the following:

A. Repair or replacement required as a

result of

(1) accident,

(2) misuse,

(3) repairs improperly performed or

replacements improperly installed,

(4) use of replacement parts or

accessories not conforming to aprilia

specifications which adversely affect

performance and/or

(5) use in competitive racing or related

events.

B. Inspections, replacement of parts and

other services and adjustments

required for required maintenance.

C. Any motorcycle on which the odometer

mileage has been changed so that

actual mileage cannot be readily

determined.

III. LIMITED LIABILITY

A. The liability of aprilia under this

Emission Control System Warranty is

limited solely to the remedying of

defects in material or workmanship by

an authorized aprilia motorcycle dealer

at its place of business during

customary business hours. This

warranty does not cover inconvenience

or loss of use of the motorcycle or

transportation of the motorcycle to or

from the aprilia dealer.

aprilia SHALL NOT BE LIABLE FOR

ANY OTHER EXPENSES, LOSS OR

DAMAGE, WHETHER DIRECT,

INCIDENTAL, CONSEQUENTIAL OR

EXEMPLARY ARISING IN

CONNECTION WITH THE SALE OR

USE OF OR INABILITY TO USE THE

aprilia MOTORCYCLE FOR ANY

PURPOSE. SOME STATES DO NOT

ALLOW THE EXCLUSION OR

LIMITATION OF ANY INCIDENTAL OR

CONSEQUENTIAL DAMAGES, SO

THE ABOVE LIMITATIONS MAY NOT

APPLY TO YOU.

B. NO EXPRESS EMISSION CONTROL

SYSTEM WARRANTY IS GIVEN BY

aprilia EXCEPT AS SPECIFICALLY

SET FORTH HEREIN. ANY EMISSION

CONTROL SYSTEM WARRANTY

IMPLIED BY LAW, INCLUDING ANY

WARRANTY OF MERCHANTABILITY

OR FITNESS FOR A PARTICULAR

PURPOSE, IS LIMITED TO THE

EXPRESS EMISSION CONTROL

SYSTEM WARRANTY TERMS

STATED IN THIS WARRANTY. THE

FOREGOING STATEMENTS OF

WARRANTY ARE EXCLUSIVE AND IN

LIEU OF ALL OTHER REMEDIES.

SOME STATES DO NOT ALLOW

LIMITATIONS ON HOW LONG AN

IMPLIED WARRANTY LASTS SO THE

ABOVE LIMITATIONS MAY NOT

APPLY TO YOU.

C. No dealer is authorized to modify this

aprilia Limited Emission Control

System Warranty.

IV.LEGAL RIGHTS. THIS WARRANTY

GIVES YOU SPECIFIC LEGAL

RIGHTS, AND YOU MAY ALSO HAVE

OTHER RIGHTS WHICH VARY FROM

STATE TO STATE.

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15

use and maintenance TUONO 1000

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V. THIS WARRANTY IS IN ADDITION TO

THE aprilia LIMITED MOTORCYCLE

WARRANTY.

VI.ADDITIONAL INFORMATION. Any

replacement part that is equivalent in

performance and durability may be

used in the performance of any

maintenance or repairs. However,

aprilia is not liable for these parts. The

owner is responsible for the

performance of all required

maintenance. Such maintenance may

be performed at a service

establishment or by any individual. The

warranty period begins on the date the

motorcycle is delivered to an ultimate

purchaser.

aprilia s.p.a.

via G. Galilei, 1

30033 Noale (VE) Italy

aprilia USA, Inc.

109 Smoke Hill Lane, Suite 190

Woodstock, GA 30188

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16

GENERAL INSTRUCTIONS

The operations preceded by this

symbol must be repeated also on

the opposite side of the vehicle.

If not expressly indicated otherwise, for the

reassembly of the units repeat the

disassembly operations in reverse order.

The terms “right” and “left” are referred to

the rider seated on the vehicle in the

normal riding position.

WARNING

The competition adjustment must be used

in organized racing or circular course

competitive event, under the auspices of a

recognized sanctioning body or by permit

issued by the local governmental authority

having jurisdiction. It is strictly forbidden

to use the competition adjustment while

riding the vehicle on public streets, roads,

or highways.

NOTE Immediately after purchasing the

vehicle, write down the identification data

provided in the SPARE PARTS

IDENTIFICATION LABEL in the table

below. This label is positioned on the left

side of the frame; to be able to read it,

remove the rider seat, see page 108

(REMOVING THE RIDER SEAT).

This information indicates:

– YEAR = year of manufacture (Y, 1, 2, …);

– I.M. = modification code (A, B, C, …);

– COUNTRY CODE = country of approval (I,

UK, A, …).

and must be provided to the Local aprilia

Dealer as reference information for the

purchase of spare parts or specific

accessories of the model you have

purchased.

In this manual the various versions are

indicated by the following symbols:



catalytic version

optional

VERSION:

Italy Singapore

United

Kingdom

Slovenia

Austria Israel

Portugal South Korea

Finland Malaysia

Belgium Chile

Germany Croatia

France Australia

Spain United States

of America

Greece Brazil

Holland South Africa

Switzerland New Zealand

Denmark Canada

Japan

I

SGP

UK

SLO

A

IL

P

ROK

SF

MAL

B

RCH

D

HR

F

AUS

E

USA

GR

BR

NL

RSA

CH

NZ

DK

CDN

J

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CONTENTS

FOREWORD.............................................. 2

INTRODUCTION....................................... 2

SAFETY WARNINGS ................................ 3

GENERAL SAFETY RULES ...................... 3

CARBON MONOXIDE.............................................3

HOT COMPONENTS...............................................3

USED ENGINE OIL..................................................3

BRAKE FLUID...........................................................4

CLUTCH FLUID........................................................4

COOLANT.................................................................4

BATTERY HYDROGEN GAS AND

ELECTROLYTE........................................................4

WARNING - PRECAUTIONS - GENERAL

ADVICE .................................................... 5

REPORTING DEFECTS THAT AFFECT SAFETY5

ROAD REGULATIONS

AND USE OF THE VEHICLE..................................5

NOISE EMISSION WARRANTY.............................5

INFORMATION ON THE NOISE AND EXHAUST

GAS EMISSION CONTROL SYSTEM...................5

TAMPERING WARNING.........................................5

PROBLEMS THAT MAY AFFECT VEHICLE

EMISSIONS ..............................................................6

VEHICLE IDENTIFICATION NUMBER (V.I.N.)

(FRAME NUMBER)..................................................6

INFORMATION CONTAINED IN THE VEHICLE

IDENTIFICATION NUMBER....................................6

DIGIT MEANING.......................................................7

POSITION OF THE ADHESIVE WARNING

LABELS.....................................................................8

ADHESIVE WARNING LABELS CHART...............9

CALIFORNIA EVAPORATIVE EMISSION

SYSTEM..................................................................11

APRILIA S.P.A. - EMISSION CONTROL SYSTEM

WARRANTY STATEMENT ...................................12

MANUFACTURER’S EMISSIONS SYSTEM

WARRANTY COVERAGE.....................................12

OWNER’S WARRANTY

RESPONSIBILITIES...............................................12

APRILIA S.P.A. - LIMITED

WARRANTY ON EMISSION

CONTROL SYSTEM..............................................13

GENERAL INSTRUCTIONS .................... 16

CONTENTS ............................................................17

BASIC SAFETY RULES ........................................20

CLOTHING..............................................................25

ACCESSORIES......................................................26

LOAD.......................................................................26

ARRANGEMENT OF THE MAIN

ELEMENTS ............................................28

ARRANGEMENT OF THE

INSTRUMENTS/CONTROLS ...................30

Instruments and indicators................... 31

INSTRUMENT AND INDICATOR TABLE............32

MULTIFUNCTION COMPUTER...........................34

SERVICE INTERVAL.............................................40

ALARM DISPLAY...................................................40

CONTROLS ............................................41

CONTROLS ON THE LEFT HAND GRIP............ 41

CONTROLS ON THE RIGHT HAND GRIP .........42

IGNITION SWITCH ................................................43

STEERING LOCK ..................................................43

UNLOCKING/LOCKING THE PASSENGER

SEAT/SEAT COVER..............................................44

GLOVE/TOOL KIT COMPARTMENT...................45

LUGGAGE RACK FASTENINGS.........................45

SPECIAL TOOLS ..................................................46

MAIN COMPONENTS .............................47

FUEL........................................................................47

LUBRICANTS .........................................................48

BRAKES..................................................................50

DISC BRAKES........................................................51

FRONT BRAKE......................................................52

REAR BRAKE.........................................................53

CLUTCH..................................................................55

ADJUSTING THE CLUTCH LEVER.....................58

ADJUSTING THE FRONT BRAKE LEVER......... 58

ADJUSTING THE SHIFT PEDAL ......................... 58

ADJUSTING THE REAR BRAKE PEDAL............59

ADJUSTING THE CLEARANCE

OF THE REAR BRAKE LEVER............................ 59

COOLANT............................................................... 60

TIRES...................................................................... 62

AUTOMATIC LIGHTS ON..................................... 63

MUFFLER/EXHAUST SILENCER........................ 63

INSTRUCTIONS FOR USE......................64

GETTING ON AND OFF THE VEHICLE.............. 64

PRE-RIDE CHECKS.............................................. 66

PRE-RIDE CHECKS CHART................................ 67

STARTING.............................................................. 68

RIDING.................................................................... 70

RUNNING-IN .......................................................... 74

STOPPING.............................................................. 75

PARKING................................................................ 75

PLACING THE VEHICLE ON THE STAND......... 77

SUGGESTIONS TO PREVENT THEFT.............. 77

MAINTENANCE ......................................79

REGULAR SERVICE INTERVALS CHART........ 81

MAINTENANCE RECORD.................................... 83

IDENTIFICATION DATA........................................ 86

JOINTS WITH CLICK CLAMPS AND WITH

SCREW-TYPE CLAMPS....................................... 86

AIR CLEANER........................................................ 87

CHECKING THE ENGINE OIL LEVEL AND

TOPPING UP.......................................................... 89

CHECKING THE SIDE STAND ............................ 91

CHECKING THE FUNCTIONING OF THE

SAFETY SWITCH ON THE SIDE STAND........... 91

CHECKING THE SWITCHES............................... 92

INSPECTING THE FRONT

AND REAR SUSPENSIONS................................. 93

FRONT SUSPENSION.......................................... 93

STEERING DAMPER ............................................ 95

REAR SUSPENSION ............................................ 95

CHECKING THE BRAKE PAD WEAR................. 97

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18

CHECKING THE STEERING................................98

CHECKING THE SWINGARM PIVOT..................98

ASSEMBLING THE PINS FOR THE REAR

SUPPORT STAND ................................................99

PLACING THE VEHICLE ON THE REAR

SUPPORT STAND ................................................99

PLACING THE VEHICLE ON THE FRONT

SUPPORT STAND ..............................................100

FRONT WHEEL....................................................100

REAR WHEEL ......................................................102

DRIVE CHAIN.......................................................105

REMOVING THE RIDER SEAT..........................108

LIFTING THE FUEL TANK ..................................108

REMOVING THE SIDE FAIRINGS.....................109

REMOVING THE SIDE FAIRINGS.....................113

REMOVING THE REARVIEW MIRRORS .........113

REMOVING THE FRONT BRAKE CALIPERS..114

REMOVING THE SIDE STAND..........................115

ADJUSTING THE THROTTLE CONTROL ........118

SPARK PLUGS.....................................................119

CHANGING FUSES .............................................121

BATTERY..............................................................123

BATTERY STORAGE..........................................124

CHECKING AND CLEANING THE

TERMINALS..........................................................124

REMOVING THE BATTERY ...............................125

CHECKING THE ELECTROLYTE LEVEL.........125

RECHARGING THE BATTERY ..........................125

INSTALLING THE BATTERY..............................126

ADJUSTING THE HEADLIGHT BEAM

VERTICALLY ........................................................127

HEADLIGHT SCREENING..................................127

ADJUSTING THE HEADLIGHT BEAM

HORIZONTALLY ..................................................128

HEADLIGHT SCREENING..................................128

BULBS ...................................................................129

CHANGING THE DASHBOARD BULBS ...........129

CHANGING THE HEADLIGHT BULBS..............130

REPLACING THE FRONT AND REAR DIRECTION

INDICATOR BULBS.............................................131

REPLACING THE LICENSE PLATE LIGHT

BULB......................................................................132

TRANSPORT ........................................ 133

DRAINING THE FUEL TANK..............................133

CLEANING ........................................... 134

LONG PERIODS OF INACTIVITY......................135

TECHNICAL DATA ............................... 137

LUBRICANT CHART............................................141

WIRING DIAGRAM TUONO 1000......................142

WIRING DIAGRAM KEY - TUONO 1000...........143

OFFICIAL DEALERS AND SERVICE

CENTERS .............................................................144

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20

BASIC SAFETY RULES

The instructions given below cover normal

operation of your vehicle and must be

carefully observed. By following these

rules you will enhance your own safety and

the safety of those around you. You will

also maximize the life and utility of your

vehicle.

Two-wheeled vehicles obviously do not

provide some of the protection provided by

automobiles, therefore it is essential that

you wear appropriate protective clothing. In

particular, never operate your vehicle

without wearing your helmet, gloves, eye

protection, a heavy jacket, sturdy footwear,

and sturdy full length pants.

However, do not assume that even the

best clothing and helmet will protect you in

the event of an upset or a crash with

another vehicle. At best, this gear provides

some protection from scrapes and

scratches, but very little, if any, impact

protection.

Be sure that you meet all the requirements

prescribed by local law, including driver’s

license, minimum age, training, insurance,

taxes, vehicle registration, license plate,

etc.

When you first receive your vehicle,

practice by riding in areas where there is

little traffic. Do not attempt to ride in heavy

traffic until you are thoroughly experienced

and riding your vehicle has become

second nature to you.

Although this vehicle is legal for use on

freeways and expressways, it is advisable

to not ride on these high-speed highways

until you are thoroughly familiar with your

vehicle, and have attained a high degree of

skill in its operation.

A new vehicle must be carefully broken in,

see page 74 (RUNNING-IN).

Before starting the engine, make sure that

the brakes, clutch, transmission and

throttle controls function properly and that

the fuel and oil supply is adequate.

The exhaust system, brakes, and some

other parts of the vehicle become very hot

during operation. Do not touch any of these

parts.

Some medicines or drugs, whether illegal

or prescription, and alcohol significantly

increase the risk of accidents. Do not ride

while you are under the influence of

alcohol or drugs, be they illicit or

prescription.

Make sure you are in good physical

condition and not ill before riding your

vehicle. Do not ride your vehicle when you

are particularly tired or fatigued. Alcohol,

drugs and fatigue are leading causes of

vehicle accidents.

Many accidents are caused by the rider’s

inexperience and lack of training. Do not

ride your vehicle until you have received

training from a recognized training

organization such as the Motorcycle Safety

Foundation. Remember that riding a two-

wheeled vehicle, though easy and fun, is

quite different from driving a car. Do not

assume that you can operate your vehicle

safely just because you are a competent

automobile driver.

Never lend your vehicle to others unless

you are sure that they are competent and

properly licensed vehicle operators.

APRum_TUONO_MY05_####.book Page 20 Monday, January 9, 2006 2:53 PM

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